1990 MAZDA 232 Workshop Manual Suplement

H CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)
Disassembty Note
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
1. Press the piston down and remove the snap ring with snap-
ring pliers.
Piston and secondary cup assembly
Caution
l Hold a rag over the master cylinder to prevent the
piston and secondary cup assembly from jumping
out.
1. Remove the piston and secondary cup assembly, spacer,
and primary cup by applying compressed air through the
clutch pipe installation hole.
One-way vaive piston and return spring
Caution
l Hold a rag over the master cylinder to prevent the
piston and spring from jumping out.
1. Remove the piston by applying compressed air through the
cylinder bore.
Assembly Note
Caution
l Before assembly, make sure all parts are completety
clean.
l Do not mix different brands of clutch ftuid.
l Do not reuse the clutch fluid that was drained.
l Apply the specified clutch fluid to the piston and
secondary cup assembty, spacer, primary cup, and
cylinder bore before assembly.
l Replace parts with new ones whenever specified to
do so.
03uot-!x-019
Piston and secondary cup assembty
1. InstaD the spring, primary cup, spacer, and piston and
secondary cup assembly, noting the proper direction of the
parts.

CLUTCH MASTER CYLlNDER (BP DOHC TURBO OR WITH A8S), CLUTCH RELEASE CYLINDER (WITH AN) H
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
t . While pressing the piston, install the snap ring.
CLUTCH RELEASE CYLINDER (WITH ABS)
PREPARATION
SST
49 0259 770B
Wrench, flare nut For disconnecting
and connecting
clutch pipe
93GOHX-724
AIR BLEEDING (WITH ABS)
I_ After installation, bleed the clutch system.
(Refer to page H-16.)
93GOHX-725
H-17

H CLUTCH UNIT
PREPARATION
SST
49 E301 060
Brake, ring gear
For removal and
i nstaI\abon of
c!utch cover and
flywl-leel
49 E301 062
Collar
(Part
of 49 E301 060) For
removal and
installation of
cIutch cover and
flywheel
49 1285 071 For
I removal of blot
Puller, bearing
Lj , - e bearing
49 0823 U72A 1 For
I installation of pilot 49 E3OI 061
Body
(Part
of 49 E301 060)
49 SE01 310
Centering tool,
clutch disc
49 1285 073
Chuck
(Part of
49 1285 071)
Installer 1 eccentric
shaft bearing @@D bearing -
For
removal and
installation of
dutch cover and
flywheel
For
support and
alrgnment of
clutch disc 7
For
removal of pilot
bearing
93GOHX-726
H-18

t .-
1
CLUTCH UNIT H
REMOVAL I fNSTALLATION
l Remove the clutch release cylinder with the clutch pipe connected.
- Do not remove the pilot bearing if not necessary.
f . Remove in the order shown in the figure, referring to Removal Note.
2. Instal! in the reverse order of removal, referring to Installation Note.
-761 BP SOHC
,E+--l BP DOHC TURBO
-; (MORI Wl-llTE TA No.2 OR
B EQUIVALENT ORGANIC
MOLYBDENUM GREASE)
1. Clutch release cylinder
2. Transaxle
Service ~......-...tl.*I.*-......*,,.**..l....... Section J3
3. Bout
4. Release bearing
5. Clutch release fork
6. Clutch cover
Removal Note _....._._._.-..._....___.._. page H-20
lnstaflation Note .._.......-..._.. . .._..._. page H-21 7. Clutch disc
Removal Note . . . . . . . .._...
Installation Note.. . . . . . . . . .
8. Pilot bearing
Removal Note . . . . . . . . . .._.
1 nstatlation Note.. . . . . __ . _.
9. Flywheel
Removal Note . . . . . . . . . . . . .
Installation Note . . . . . . . . . . . *..*.
w....
*.*..
-....
. . . . .
. . . . ..*.a.*.
page H-20
.,..I.._ page H-21
.**-. ..- page H-20
.,..... -
page H-21
. ..*.-.- page H-20
_...a-.. page H-20
H-19

C1UTCf-f UNtT
9MUOHX-032
I
03UOf-lX-028
I
93GOHX-729
I
i
Removal Note
Clutch cover and disc
1. Install the SST.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the ciutch cov-
er and disc.
Pilot bearing
1. Remove the pilot bearing with the
SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
1. Hold the flywheel with the SST.
2. Remove the flywheel.
Instalfation Note
Flywheel
1 -Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and SST.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
96403 Nmm (9.8-10.5 m-kg, 71-76 ft.lb)
PiIot bearing
Note
l Install the pilot bearing ftush with the flywheeL
I_ Install the new bearing with the SST.
03UOHX-030
H-20

CLUTCW UNIT
Clutch disc
1. Clean the clutch disc splines and main drive gear spIines;
then apply organic molybdenum grease.
2. Hold
the clutch disc in position with the SST.
Clutch cover
1. Install the SST.
2. Align the
dowel holes with the flywheel dowels.
3. Tighten the
botts evenly and gradually in the pattern shown.
Tightening torque:
18-26 N-m (1.8-2.7 m-kg, 13-20 ft-lb)
EWOHX-040
Ii-21

I

J3
MANUAL TRANSAXLE AND
TRANSFER UNIT (GSMX-R)
INDEX .........................................
J3- 2
/FEATURES] I
OUTLINE .....................................
J3- 4
OUTLINE OF CONSTRUCTION ..... J3- 4
SPECIFlCATtUNS ....................... J3- 5
TRANSAXLE AND TRANSFER UNIT J3- 5
STRUCTURAL VIEW.. ................. J3- 6
TRANSAXLE ................................ J3- 8
DOUBLE CONE SYNCHRU
MECHANlSM ........................... J3- 8
SHIFT FORKS AND SHIFT RODS . . J3- 10
iNTERLUCK MECHANISM ......... ., J3- 11
TRANSFER UNtT
.......................... J3- 12
CENTER DIFFERENTIAL ............. J3- 14
VISCOUS COUPLING
(BP DOHC TURBO). .................. J3- 20
CENTER DlFFERENTIAL LUCK
SYSTEM (MANUAL) .................. J3- 23
CENTER DIFFERENTIAL LOCK
SYSTEM (ELECTRICAL) ............. J3- 24
CENTER DIFFERENTIAL LOCK
CONTROL SWITCH ................... J3- 28
CENTER DIFFERENTIAL LUCK
ASSEMBLY
.............................. J3- 29
CENTER DIFFERENTIAL LOCK
SENSOR SWlTCH.. ................... J3- 31
IDLER GEAR SHAFI- ................... J3- 33
POWERFLOW .............................. J3- 34
TROUBLESHOOTING GUIDE ......... J3- 35 TRANSAXLE OIL .......................... J3- 36
INSPECTlON ............................. 33- 36
REPLACEMENT.. ....................... J3- 36
TRANSFER CARRIER CM .............
339 36
INSPECTION ............................. J3- 36
REPLACEMENT. ........................ J3- 36
TRANSAXLE AND
TRANSFER UNIT ........................ J3- 38
PREPARATION .......................... J3- 38
REMOVAL ................................. J3- 42
DISASSEMBLY
........................... J3- 48
INSPECTION ............................. J3- 72
ASSEMBLY ............................... J3- 75
INSTALLATION
.......................... J3-I I2
SHIFT MECHANISM.. .................... J3-119
OVERHAUL ............................... J3-119
CENTER DIFFERENTIAL
LOCK SYSTEM ........................... J3-121
SYSTEM DIAGRAM ..................... J3-121
INSPECTION ............................. J3-122
CENTER DIFFERENTIAL
LOCK MOTOR ............................ J3-123
INSPECTDN ............................. J3-123
REPLACEMENT ......................... J3-123
4x4 CONTROL UNIT.. ................... J3-126
INSPECTION ............................. 53-l 26
REPLACEMENT.. ....................... 53-l 26
CENTER DIFFERENTIAL
LOCK SWITCH ........................... J3-126
INSPECTION ............................. J3-126
REPLACEMENT ......................... J3-127
CENTER DIFFERENTIAL
LUCK SENSOR SWITCH ............. J3-127
INSPECTION ............................. J3-127
REPLACEMENT ......................... J3-127
93GOJ3-701